Floor panel

ABSTRACT

A floor panel is provided including a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated and quickly installed on the job site thereby cutting construction time and costs.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/760,432 for FLOOR AND WALL MODULAR SYSTEM filed on Nov. 13, 2018, which is incorporated by reference as if fully set forth.

FIELD OF INVENTION

The present invention relates generally to the art of building construction, and more specifically to a floor panel, and a method of assembling a floor panel.

BACKGROUND

Floors are typically built on the job site. Floors are constructed layer by layer. This piecemealed construction is tedious and time consuming, which ultimately results in higher construction costs.

SUMMARY

A floor panel is provided including a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated and quickly installed on the job site thereby cutting construction time and costs.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise floor panel arrangement shown.

FIG. 1 is a top, right perspective view of a floor panel.

FIG. 2 is an exploded view of the floor panel.

FIG. 3 is a top, right perspective view of a room including the floor panel.

FIG. 4 is a flow chart of a method of assembling a floor panel.

DETAILED DESCRIPTION

A floor panel is provided. The floor panel includes a floor chassis, an acoustic-mat layer and a gypsum concrete layer. The floor panel may be prefabricated, and can be quickly and efficiently installed at the job site thereby saving time and money.

FIG. 1 is a top, right perspective view of a floor panel 100. FIG. 1 depicts a floor panel 100 comprising a floor chassis 110, an acoustic-mat layer 120 and a gypsum concrete layer 130. As shown in FIG. 1, the acoustic-mat layer 120 is placed on top of the floor chassis 110, and the gypsum concrete layer 130 is placed on top of the acoustic-mat layer 120. The floor chassis 110 provides the load-bearing framework for the floor. The floor chassis 110 may be made from plywood, cross laminated timber (CLT), etc. The acoustic-mat layer 120 increases sound isolation and reduces impact noise. The acoustic-mat layer 120 may be made from an elastomer. The gypsum concrete layer 130 is a lightweight, fire-resistant layer. These three layers 110, 120, 130 can be produced as segments that fit together like a puzzle. For example, FIG. 1 shows three segments that fit together. The size and shape of the segments makes shipping and handling easier. The acoustic-mat layer 120 may be connected to the floor chassis 110. The acoustic-mat layer 120 may be adhered, stapled, nailed, or otherwise connected to the floor chassis 110. The gypsum concrete layer 130 may be connected to the acoustic-mat layer 120 and the floor chassis 110. The gypsum concrete layer 130 may be adhered, stapled, nailed, or otherwise connected to the acoustic-mat layer 120. Moreover, these three layers 110, 120, 130 may be pre-laminated in the factory prior to shipment to the job site. Once on the job site, the floor may be quickly and efficiently installed.

FIG. 2 is an exploded view of the floor panel 100. FIG. 2 shows the floor chassis 110, the acoustic-mat layer 120 and the gypsum concrete layer 130. The floor panel 100 may also include a flooring membrane 140 placed on top of the gypsum concrete layer 130, as shown in FIG. 2. The flooring membrane 140 may be connected to the gypsum concrete layer 130. The flooring membrane 140 may be adhered, stapled, nailed, or otherwise connected to the gypsum concrete layer 130. Moreover, the floor panel 100 may also include a finish flooring 150 placed on top of the flooring membrane 140, as shown in FIG. 2. The flooring membrane 140 may provide a moisture barrier. The flooring membrane 140 may also prevent the floor from flexing, thereby preventing cracks. The flooring membrane 140 may be made from a polymer. The finish flooring 150 is the final layer of the floor panel 100. The finish flooring 150 may be tile, hardwood, engineered hardwood, laminated wood, or carpet. The finish flooring 150 may be connected to the flooring membrane 140. The finish flooring 150 may be adhered, stapled, nailed, or otherwise connected to the flooring membrane 140. The floor chassis 110 may be the largest layer to create an edge or border. The floor chassis 110 may also include at least one opening 160 to allow plumbing, electrical wire, conduit, etc. to pass through.

FIG. 3 is a top, right perspective view of a room 200 including the floor panel 100. The floor panel 100 includes the same features, components, and embodiments previously discussed. The floor panel 100 may be installed at a job site in a room. For example, the floor panel 100 may be installed in a bathroom as shown in FIG. 3. Although a bathroom is illustrated, the floor panel 100 may be installed in a bedroom, office, family room, living room, dining room, kitchen, basement, etc. Because the floor panel 100 may be prefabricated, installation is quick and efficient. The room 200 includes wall frames 210. The wall frames 210 may include a top plate, a bottom plate, and a plurality of vertical studs between the top plate and bottom plate. The openings 160 in the floor chassis 110 may align with openings 220 in the wall frame 210 for the mechanical, electrical, and plumbing utilities. The openings 160, 220 allow the mechanical, electrical, and plumbing utilities to run from floor to floor without interference. The floor chassis 110 may be the largest layer to create an edge or border to allow the wall frames 210 to connect to the floor chassis 110 (not visible in FIG. 3). The floor panel 100 may be used to align the walls of a room.

FIG. 4 is a flow chart of a method of assembling a floor panel 400. In step 410, the acoustic-mat layer 120 is connected to the floor chassis 110. The acoustic-mat layer 120 may be adhered, stapled, nailed, or otherwise connected to the floor chassis 110. In step 420, the gypsum concrete layer 130 is connected to the acoustic-mat layer 120 and the floor chassis 110. The gypsum concrete layer 130 may be adhered, stapled, nailed, or otherwise connected to the acoustic-mat layer 120 and the floor chassis 110. Alternatively, the acoustic-mat layer 120 may be connected to the gypsum concrete layer 130. The acoustic-mat layer 120 may be adhered, stapled, nailed, or otherwise connected to the gypsum concrete layer 130. Then, the combined gypsum concrete layer 130 and acoustic-mat layer 120 may be connected to the floor chassis 110. In step 430, the combined floor chassis 110, acoustic-mat layer 120, and gypsum concrete layer 130 may be cut into segments to make shipping and handling easier. Alternatively, the layers 110, 120, 130 may be cut into segments prior to connecting the layers 110, 120, 130. In step 440, the combined floor chassis 110, acoustic-mat layer 120, and gypsum concrete layer 130 may be laminated together.

The method of assembling 400 may also include step 450 of connecting a flooring membrane 140 to the gypsum concrete layer 130. The method of assembling 400 may also include step 460 of connecting a finish flooring 150 to the flooring membrane 140. The method may also include step 470 of shipping the floor panel 100 to a job site. The method may also include step 480 of installing the floor panel 100 in a room, such as a bathroom, bedroom, office, dining room, basement, etc. The steps in the method 400 described herein and illustrated in the flow chart in FIG. 4 may be accomplished in a different order than the order presented.

Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the floor panel and the method of assembling the floor panel without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein. 

What is claimed is:
 1. A floor panel comprising: a floor chassis; an acoustic-mat layer connected to the floor chassis; and a gypsum concrete layer connected to the acoustic-mat layer.
 2. The floor panel of claim 1, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are segments that fit together.
 3. The floor panel of claim 1, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are laminated together.
 4. The floor panel of claim 1, further comprising a flooring membrane connected to the gypsum concrete layer.
 5. The floor panel of claim 4, further comprising a finish flooring connected to the flooring membrane.
 6. The floor panel of claim 1, wherein the floor chassis includes at least one opening.
 7. The floor panel of claim 1, wherein the floor panel is prefabricated.
 8. A room modular system comprising: a room including at least one wall frame including a top plate, a bottom plate, a plurality of studs; and a floor panel comprising a floor chassis, an acoustic-mat layer on top of the floor chassis, and a gypsum concrete layer on top of the acoustic-mat layer; wherein the bottom plate of the at least one wall frame is connected to the floor chassis.
 9. The room modular system of claim 8, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are segments that fit together.
 10. The room modular system of claim 8, wherein the floor chassis, the acoustic-mat layer, and the gypsum concrete layer are laminated together.
 11. The room modular system of claim 8, further comprising a flooring membrane connected to the gypsum concrete layer.
 12. The room modular system of claim 11, further comprising a finish flooring connected to the flooring membrane.
 13. The room modular system of claim 8, wherein the floor panel is prefabricated.
 14. The room modular system of claim 8, wherein the floor chassis includes at least one opening.
 15. The room modular system of claim 14, wherein the bottom plate includes at least one other opening that aligns with the at least one opening of the floor chassis.
 16. A method of assembling a floor panel comprising: connecting an acoustic-mat layer to a floor chassis; connecting a gypsum concrete layer to the acoustic-mat layer and the floor chassis; cutting the floor chassis, the acoustic-mat layer, and the gypsum concrete layer into segments configured to fit together; and shipping the floor panel to a job site.
 17. The method of claim 16 further comprising connecting a floor membrane to the gypsum concrete layer.
 18. The method of claim 17 further comprising connecting a finish flooring to the floor membrane and the gypsum concrete layer.
 19. The method of claim 17 further comprising laminating the floor chassis, the acoustic-mat layer, and the gypsum concrete layer.
 20. The method of claim 17 further comprising installing the panel in a room at the job site. 